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Probably the author sort value in calibre differs from the author value but only in letter case, which calibre thinks is OK. For example, almost certainly some books have an author sort of "Nelson DeMille" and others "Nelson Demille". Because the Android file system is case sensitive, the difference matters.
While testing I discovered that the edit metadata dialog will not show you letter case differences. For example, Assume an author "Nelson Demille". The author_sort box will show "Nelson Demille" even if the database really contains ""Nelson DeMille". You cannot see the case difference, but it is there. I am discussing this with Kovid to see if this behavior is intentional.
One way to find books where the author sort differs from what it should be only by case is to use the quality check plugin. The option Check metadata/Check author sort will mark all the books where author sort differs from what it "should" be, even if only by case.
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