I've a similar problem with my Toshiba A100-155:
Test case:
- boot with killswitch=on (wireless=off) and lan connected
- lsmod  returns the module loaded but not used
- no process running called /sbin/ipw3945d-2.6.22-12-generic
- nm-applet says nothing about wireless

[    3.544000] ipw3945: Intel(R) PRO/Wireless 3945 Network Connection driver 
for Linux, 1.2.2mp.ubuntu1
[    3.544000] ipw3945: Copyright(c) 2003-2006 Intel Corporation
[    5.192000] ipw3945: Detected Intel PRO/Wireless 3945ABG Network Connection
[    5.192000] ipw3945: ipw3945.ucode load failed: Reason -2
[    5.192000] ipw3945: Could not read microcode: -2
[    5.192000] ipw3945: probe of 0000:05:00.0 failed with error -2

If i rmmod and modprobe manually everything goes fine...

[  620.808000] ipw3945: Intel(R) PRO/Wireless 3945 Network Connection driver 
for Linux, 1.2.2mp.ubuntu1
[  620.808000] ipw3945: Copyright(c) 2003-2006 Intel Corporation
[  620.808000] ipw3945: Detected Intel PRO/Wireless 3945ABG Network Connection
[  622.680000] ipw3945: Detected geography ABG (13 802.11bg channels, 23 
802.11a channels)
[  870.016000] ipw3945: Radio Frequency Kill Switch is On:
[  907.896000] ipw3945: Detected geography ABG (13 802.11bg channels, 23 
802.11a channels)

-- 
[gutsy] ipw3945-based wireless doesn't work after booting with wireless switch 
off
https://bugs.launchpad.net/bugs/121415
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