For anyone curious here is an easy visual explanation of what is actually happening to her in the background if she's knocked out as a 'Permanently Hostile' NPC in ACT I;

*As can be seen when she is flagged as 'Permanently Hostile' in ACT I - the game by default treats her as non-interactable from that moment on. The only way this gets fixed is if she auto-initiates her rescue dialogue in ACT II (which properly updates her NPC state). But if her dialogue cannot be accessed, her NPC state cannot update therefore Minthara remains eternally non-interactable and thus unobtainable.*

[Linked Image from i.imgur.com]

Minthara's Recruitment Blocker (Goblin Camp Knockout) report has been updated with this info as well.