That was a relatively common cache problem in the past.
Open your explorer and navigate to C:\Documents and Settings\All Users\Application Data\Stardock\Impulse\backup.
There should be a bunch of files there with .impulse extensions. Move everything out of that folder to a safe backup folder and try downloading and archiving again.
If it works, you can delete the stuff you moved out. If not, you haven't lost anything and can move it all back.
I thought the cache problem had been resolved a while back. After clearing the cache, you might want to double check to see if you have the latest version.