The context in which these downloads are used is:
User has purchased items (software, eBooks) and goes to checkout page.
User is redirected to PayPal for payment.
User is redirected back to our website. There the payment status is checked, and, if OK the download starts automatically (redirecto to getProduct.php page).
If the payment status is changed to OK later, the user receives a download notification by email (link to getProduct.php page).
In both cases I use the URL: .../getProduct.php?downloadId=randomString
The random string is unique for the specific order.
In case #1 I can workaround it by adding a 2nd, completely random parameter. However, case #1 only occurs in my dev environment 😉.
Case #2 is rather annoying, because this is the life situation. Customers can have ANY browser and ANY browser settings. Fortunately, case #2 is limited to IE browsers. And yes, I am working with XP / IE SP2. I think you are right, it is probably the popup blocker that blocks the download.
The remaining question now, is how to force a download on redirect, also with IE SP2. Are there any known workarounds that don't require specific browser settings but force the download using headers ?