I seem to be having the same problem unzipping themes as well. I don't believe it is the download process but the unpacking of the downloaded .zip file. I am using Winzip (v9), and have tried multiple theme files and an infusion with same results.
Just thought I would add, I had same trouble trying to download COPPA infusion, have never had this problem before, using IE8, I downloaded Chrome and all worked well, problem solved.
This could be an issue with the program used to zip the files maybe?
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