What interface are you using currently? If the issue goes away when you reset SONAR's audio engine, that certainly sounds like a driver problem as opposed to power supply, ground loops or other analog issues. Since Ivory uses disk-streaming of samples IIRC, you'll also want to make sure your disk is are managing the load okay, too. And check your DPC latency (Google dpclat and/or latencymon).
As far as a new interface goes, if you don't need portability or laptop compatibility, I recommend getting something that uses a PCIe bus card rather than USB or FW, preferably with MIDI port(s) also on the card (or breakout box) to further reduce total latency when playing live. The best FW interfaces seem to be capable of delivering quite low latencies, but you have to pay for it.
I haven't surveyed the market lately, so I really can't make a specific recommendation. I loved my E-MU 1820m in terms of performance, features and sound quality, but driver support was poor toward the end of its life and it eventually suffered a hardware failure of some sort. Nevertheless, I would have gone that way again but the new models didn't have the ADAT I/O I needed. I ended up with a MOTU 2408 PCIe audio interface but my MIDI ports are now via USB (also MOTU) and have twice the transmission time of the E-MU (7ms round-trip vs. 3.5).