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I'm not sure how much this will help to understand, but the basic problem is that tables in rich text are limited to 255 rows and 64 columns (see Domino Limits for this sort of information). So, the time you get into trouble is when HTML is converted to rich text and the table exceeds those limits. In Notes 6/7, MIME e-mails (which are essentially HTML) are always converted to rich text, so you always have the problem. My understanding is that Notes 8 added the option of an IE rendering engine for the MIME, and I am not quite sure whether that avoids the problem or not, but it would be worth investigating.
The only other workaround is to use web mail, which does not need to render to rich text.
Feedback response number BLAS7CHRMS created by ~Wei Brekrotheretsi on 03/07/2008