I got an error that was similar if not exactly this after some of the recent mail updates. It turned out that the mail key needs to be anything but NULL in the DB which is not the case for any toon made before the SVN update came out. It's like you said, it didn't happen all the time, but was often enough I started digging around some and saw a post somewhere on these forums recently about the same thing. Changing it fixed my issues, so with some luck it will for you too.
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