Abstract
Promising separator behavior in a controlled lithium-sulfur cell does not automatically transfer to different chemistries, formats, manufacturing lines, or duty cycles. This review specifies the evidence boundaries that govern AI-supported scale-up. Material composition, pore architecture, polysulfide interaction, cell assembly, cycling protocol, sensing, and decision use are represented as distinct but linked domains. Physics-informed learning and domain adaptation may bridge selected gaps, while out-of-distribution detection and calibrated uncertainty identify when a bridge is unsupported. The synthesis requires each model to declare its validation envelope and predefine triggers for recalibration, shadow testing, new cell studies, or production re-qualification. It emphasizes that an unchanged prediction interface can hide substantial changes in data generation or error consequences. Provenance records connect separator batches and test conditions to model versions and release decisions. This article does not generate a new scale-up result. Its contribution is a traceable AI translation framework that separates defensible transfer from extrapolation and turns revalidation from an informal response into a planned engineering control.
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