After looking at your code when I returned to my computer this evening and not finding anything amiss, I came to the conclusion that the module's Settings hashtable was not getting populated for some reason - glad you found out why.

Assuming that your "small" controls which your "large container" control loads also inherit from PortalModuleBase, you will need to initialize the "small" control's ModuleConfiguration property to that of the container module. This will serve (among other things) to pass the container's ModuleId and TabModuleId into the "small" control. Once the parent's ModuleConfiguration is available, the child's Settings hashtable should get loaded automatically the first time it is accessed in code. If you are using localization, you may also want the child control to draw its localized key-value pairs from the same .resx as the parent.  Typical code will be similar to:

Dim ctl As Control = LoadControl (ctlPath)
If ctl Is Nothing Then
    'Handle error - could not load control
Else
    With CType(ctl, DotNetNuke.Entities.Modules.PortalModuleBase)
          .ModuleConfiguration = Me.ModuleConfiguration
          .LocalResourceFile = Me.LocalResourceFile
    End With
End If

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Bill, WESNet Designs
Team Lead - DotNetNuke Gallery Module Project (Not Actively Being Developed)
Extensions Forge Projects . . .
Current: UserExport, ContentDeJour, ePrayer, DNN NewsTicker, By Invitation
Coming Soon: FRBO-For Rent By Owner

That would be ModuleId.  Also take note that the ModuleController.SynchronizeModule(ByVal ModuleId as Integer) method was introduced in DNN version 04.06.xx or so. If your module needs to be compatible with an earlier version of DNN you will have to use the now deprecated Modules.PortalModuleBase.SynchronizeModule() method. I found this out the hard way when I released a module claiming compatibility with DNN 04.05.05.

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Bill, WESNet Designs
Team Lead - DotNetNuke Gallery Module Project (Not Actively Being Developed)
Extensions Forge Projects . . .
Current: UserExport, ContentDeJour, ePrayer, DNN NewsTicker, By Invitation
Coming Soon: FRBO-For Rent By Owner