I’m pretty sure what you’re writing to the SD card is a raw binary image, not something with a filesystem that you can browse with a file explorer; otherwise, you’d just be formatting as something like FAT16 or FAT32 and extracting files from a zip archive to the SD card.
The OSSC looks for and verifies a checksum of the binary image, so, if it actually is corrupt when you try to do the firmware update, the OSSC won’t apply it.
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