Blocksize is not the same as volume/partition/file size
(http://en.wikipedia.org/wiki/Block_%28data_storage%29). A file system
usually has a block size associated with it. In general terms, when data
is pulled off the device it will usually pull off the whole block at the
same time. Since related data is usually close by, the future accesses
won't have to go back to this disk because that block is already cached
in memory. The volume size is the product of the blocksize and the
number of blocks.

Persistence works by creating a large file (casper-rw) with dd. The 2048
MB block size limit is a limitation of dd. Almost nobody would be using
a block size that large, unless they are only working with large multi-
gigabyte files of contiguous data. Using large blocks will be
inefficient in most normal situations. This is why most filesystems
default to a blocksize in the 1KB-4KB range. The fact that usb-creator
is trying to create persistence files with an arbitrary block size is
definitely a bug.

Now as far as FAT32 is concerned it is capable of have larger than 2 GB
volume sizes, but it does have a hard limit of 4 GB (2^32) for a single
file. Usb-creator creates a file called casper-rw with dd and formats it
to ext3. This file is mounted by ubuntu at boot time and is used to
store persistent changes. However the casper-rw file is a single file
saved on the FAT32 filesystem of the USB drive, and thus it cannot be
larger than 4 GB.

With the current blocksize bug in usb creator you will get an error
about 'invalid blocksize' in your usb-creator log, but it will exit
normally. If you fix usb-creator so that it uses a reasonable block size
like 1 KB, then you will be able to go about 2048 MB without an error.
However, if you go above 4 GB then you will run into the file size
limitation of FAT32. You will see an error in your usb-creator log where
it calls dd. It will write the file right up to 4 GB and then it will
give some error about the wrong file size or out of space or something
like that. The 4 GB limit is not a bug and is a technological limit of
FAT32. Hopefully the patches in the bug report I linked to will get
incorporated to make this clear to the user.

-- 
No persistence with USB Creator in Ubuntu 8.10
https://bugs.launchpad.net/bugs/302485
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