fix(tabs): wrap case clusters box by box and never route a lineage line through a tab

With tabArrangement 'case' at 1440px (nine tabs in four cases), the lineage
routes ran horizontally through the middle of tabs, cluster labels and box
borders. #538's clusters are `max-width: 100%` boxes that may shrink, so in
the one-line strip every box squeezed and wrapped inside itself (a one-tab
case's swatch alone on a line above its tab). The strip then never
overflowed, so updateTabOverflowMode() never wrapped it, and #544's routing
room (`.lineage-tree.tabs-auto-wrap`: row gap and spine channel) never
applied. computeLineageRows grouped the squeezed tabs by top alone into rows
that overlap (10-40, 20-50, 42-74), and gapUnder put the first row's gap at
y 30, inside the tabs below it.

- On the desktop header strip a cluster keeps its width, so clusters that do
  not fit overflow and the strip wraps box by box; the boxes' own gaps read
  --lineage-row-gap, so the routes run between box rows and through the
  spine channel. A case wider than the whole strip still wraps inside its
  box, and now wraps the strip too (`_tabClustersWrapInside`, the new
  `innerWrap` input of shouldAutoWrapTabs), so its inner rows get the gap.
- computeLineageRows never returns overlapping rows: tabs whose spans
  overlap are one row. gapUnder returns null when there is no real gap, and
  a route with no gap is not drawn. A final pass drops any route with a
  segment inside a tab, so no arrangement can draw a line through a tab
  (a layout without the room loses lines instead). Pinned with the squeezed
  rects measured live.

At 1920px, where the clusters fit on one line, nothing changes.

Co-Authored-By: Claude Opus 5.5 (1M context) <noreply@anthropic.com>

src/web/public/app.js

@@ -6359,12 +6359,29 @@ class CodemanApp {
           tabCount: this.sessions.size,
           scrollWidth: container.scrollWidth,
           clientWidth: container.clientWidth,
+          innerWrap: container.classList.contains('tabs-clusters') && this._tabClustersWrapInside(container),
         })
       : container.scrollWidth > container.clientWidth + 1;
 
     container.classList.toggle('tabs-auto-wrap', shouldWrap);
   }
 
+  /**
+   * True when a case cluster in the header strip wraps inside its own box: a case
+   * wider than the whole strip (styles.css caps a box at the strip's width). The
+   * strip then has rows although it never overflows, so it must still wrap, or
+   * the lineage routing room (`.lineage-tree.tabs-auto-wrap`) is never reserved
+   * and the routes have no gap between the box's rows to run in. Read right
+   * after the overflow measure, so layout is already clean.
+   */
+  _tabClustersWrapInside(container) {
+    for (const box of container.querySelectorAll(':scope > .tab-cluster')) {
+      const tabs = box.querySelectorAll(':scope > .session-tab');
+      if (tabs.length > 1 && tabs[tabs.length - 1].offsetTop > tabs[0].offsetTop + 4) return true;
+    }
+    return false;
+  }
+
   // Middle-click closes a tab, mirroring browser tab strips. Session tabs go
   // through requestCloseSession (the same confirm modal as the x button), web
   // tabs through closeWebviewTab (same as theirs). Delegated on the container:

src/web/public/constants.js

@@ -207,6 +207,9 @@ function shouldAutoWrapTabs(input) {
   if (!input || input.deviceType !== 'desktop') return false;
   if (input.manualTwoRows) return false;
   if ((input.tabCount || 0) < 2) return false;
+  // A box in the strip already wraps inside itself (a case cluster wider than the
+  // whole strip): the strip has rows although nothing overflows.
+  if (input.innerWrap) return true;
 
   const scrollWidth = Number(input.scrollWidth) || 0;
   const clientWidth = Number(input.clientWidth) || 0;
@@ -330,6 +333,12 @@ function computeTabScrollLeft(input) {
 // left out of `routes`. `.session-tabs` scrolls, so a scrolled-out tab still HAS a
 // rect, lying over the logo or the header buttons. Skipping is honest; clamping
 // would point at a tab that is not there.
+//
+// A child is also left out when its route has nowhere to run: rows whose spans
+// overlap are one row (no gap between them), a row with no gap under it routes
+// nothing, and a route that would still cross a tab is dropped whole. So no tab
+// arrangement can put a line through a tab; a layout without the reserved room
+// loses lines instead.
 const LINEAGE_CORNER_RADIUS_PX = 10;
 // Families drawn together take separate lanes: gap lines this far apart, spines
 // LINEAGE_SPINE_STEP_PX apart.
@@ -342,6 +351,8 @@ const LINEAGE_SPINE_STEP_PX = 4;
 // The last row has no row below it; with no strip rect to measure, its gap is
 // taken to be this deep.
 const LINEAGE_LAST_GAP_PX = 12;
+// Narrower than this, the space between two rows is not a gap a route can run in.
+const LINEAGE_MIN_GAP_PX = 2;
 const LINEAGE_ROW_TOLERANCE_PX = 6;
 const LINEAGE_STRIP_TOLERANCE_PX = 4;
 // How far the vertical rail's track sits in from the rail's left edge. It has to
@@ -385,21 +396,37 @@ function lineageRect(rect) {
  * Group tab rects into the strip's visual rows, top to bottom. A row spans from its
  * highest top to its LOWEST bottom, so a taller tab (the active one) sets the row's
  * gap for everyone in it.
+ *
+ * ⚠ Rows never overlap. Tabs whose spans overlap are in one row however far apart
+ * their tops are: case clusters stack and centre tabs inside their boxes, and two
+ * overlapping "rows" put the gap of one in the middle of the other's tabs.
  */
 function computeLineageRows(rects) {
-  const rows = [];
+  const sorted = [];
   for (const raw of rects || []) {
     const r = lineageRect(raw);
-    if (!r) continue;
+    if (r) sorted.push(r);
-    const row = rows.find((candidate) => Math.abs(candidate.top - r.top) <= LINEAGE_ROW_TOLERANCE_PX);
+  }
-    if (row) {
+  sorted.sort((a, b) => a.top - b.top);
-      row.top = Math.min(row.top, r.top);
+  const rows = [];
+  for (const r of sorted) {
+    // Sorted by top, so only the last row can take this rect, and merging into it
+    // keeps every earlier row clear of it.
+    const row = rows[rows.length - 1];
+    if (row && (r.top < row.bottom || r.top - row.top <= LINEAGE_ROW_TOLERANCE_PX)) {
       row.bottom = Math.max(row.bottom, r.bottom);
     } else {
       rows.push({ top: r.top, bottom: r.bottom });
     }
   }
-  return rows.sort((a, b) => a.top - b.top);
+  return rows;
+}
+
+/** Does an axis-aligned segment pass through the inside of a rect? Touching an edge is fine. */
+function lineageSegmentCrosses([x1, y1], [x2, y2], r) {
+  const eps = 0.5;
+  if (Math.max(x1, x2) <= r.left + eps || Math.min(x1, x2) >= r.right - eps) return false;
+  return Math.max(y1, y2) > r.top + eps && Math.min(y1, y2) < r.bottom - eps;
 }
 
 /**
@@ -503,19 +530,23 @@ function computeLineageTree(input) {
   const rowOf = (r) => rows.findIndex((row) => r.cy >= row.top - tol && r.cy <= row.bottom + tol);
   const laneOffset = (lane - (laneCount - 1) / 2) * LINEAGE_LANE_STEP_PX;
   // Y of the gap under row i, this family's lane. The offset is clamped so a busy
-  // gap never pushes a lane into the tabs on either side of it.
+  // gap never pushes a lane into the tabs on either side of it. Null when there is
+  // no gap: the row is not found, or the next row starts (nearly) where it ends.
   const gapUnder = (i) => {
     const row = rows[i];
+    if (!row) return null;
     const next = rows[i + 1];
     let bottom;
     if (next) bottom = next.top;
     else if (strip && strip.bottom > row.bottom + 1) bottom = strip.bottom;
     else bottom = row.bottom + LINEAGE_LAST_GAP_PX;
+    if (!(bottom - row.bottom >= LINEAGE_MIN_GAP_PX)) return null;
     const half = Math.max(0, (bottom - row.bottom) / 2 - 1);
     return (row.bottom + bottom) / 2 + Math.max(-half, Math.min(half, laneOffset));
   };
   const pRow = rowOf(parent);
   const gp = gapUnder(pRow);
+  if (gp === null) return { routes };
   // The spine runs from one row's gap to another's, so it only ever passes BESIDE
   // rows after the first, and only their tabs bound it. The first row may start
   // left of the channel (grouped by state it starts after the brand and a label
@@ -524,16 +555,23 @@ function computeLineageTree(input) {
   const lowerLefts = [parent, ...visible.map((c) => c.rect), ...(input?.tabs || []).map(lineageRect)]
     .filter((r) => r && rowOf(r) > 0)
     .map((r) => r.left);
-  const minLeft = lowerLefts.length ? Math.min(...lowerLefts) : Math.min(parent.left, ...visible.map((c) => c.rect.left));
+  const minLeft = lowerLefts.length
+    ? Math.min(...lowerLefts)
+    : Math.min(parent.left, ...visible.map((c) => c.rect.left));
   const channelLeft = Number(input?.spineLeft);
   const spineBase = strip
     ? Math.max(strip.left, Number.isFinite(channelLeft) ? channelLeft : strip.left)
     : minLeft - LINEAGE_SPINE_INSET_PX * 2;
   const spineX = Math.min(spineBase + LINEAGE_SPINE_INSET_PX + lane * LINEAGE_SPINE_STEP_PX, minLeft - 2);
 
+  // Every tab a route must stay out of. A segment can only cross one if the rows
+  // above failed to describe the layout, so this is a backstop that drops the
+  // route whole rather than drawing it through a tab.
+  const obstacles = [parent, ...visible.map((c) => c.rect), ...(input?.tabs || []).map(lineageRect)].filter(Boolean);
   for (const { id, rect } of visible) {
     const cRow = rowOf(rect);
     const gc = gapUnder(cRow);
+    if (gc === null) continue;
     const points =
       cRow === pRow
         ? [
@@ -550,6 +588,10 @@ function computeLineageTree(input) {
             [rect.cx, gc],
             [rect.cx, rect.bottom],
           ];
+    // The rounded corners cut inside each turn by a few pixels at most
+    // (lineagePolylinePath), so the segments are what has to clear the tabs.
+    const blocked = points.some((p, i) => i > 0 && obstacles.some((r) => lineageSegmentCrosses(points[i - 1], p, r)));
+    if (blocked) continue;
     const d = lineagePolylinePath(points, radius);
     if (d) routes.push({ id, points: roundPoints(points), d, endX: r1(rect.cx), endY: r1(rect.bottom) });
   }

src/web/public/styles.css

@@ -20891,6 +20891,21 @@ html[data-session-list='sidebar'][data-sidebar='collapsed'] .session-sidebar .ta
   padding-left: 3px;
 }
 
+/* Desktop: a cluster keeps its width, so clusters that do not fit on one line
+   overflow the strip and updateTabOverflowMode() wraps it box by box. Allowed
+   to shrink, every box squeezed and wrapped inside itself instead (a one-tab
+   case's swatch alone on a line above its tab), the strip never overflowed,
+   and the lineage routing room, which needs a wrapped strip, never applied:
+   the routes ran through tabs, labels and box borders. Only a case wider than
+   the whole strip still wraps inside its box (max-width: 100%), and the strip
+   wraps around it too (_tabClustersWrapInside). The narrower screens keep
+   their scrolling strip. */
+@media (min-width: 768px) {
+  .session-tabs-host > .session-tabs.tabs-clusters > .tab-cluster {
+    flex-shrink: 0;
+  }
+}
+
 /* Side rail and sidebar: every case is a section with its label on top
    (vertical space is cheap there, so a one-tab case is labelled too). The
    label goes first by `order`, because a sorted rail orders the rows inside

test/session-lineage-lines.test.ts

@@ -380,6 +380,87 @@ describe('lineage tree geometry: header strip', () => {
   });
 });
 
+describe('lineage tree geometry: never through a tab, in any arrangement', () => {
+  // Measured live (1440x900, tabArrangement 'case', nine tabs in four cases) before
+  // the case boxes kept their width: every box squeezed and wrapped inside itself,
+  // so tabs sat at tops 10, 20, 42 and 43 with spans that overlap. The old rows
+  // (grouped by top alone) put the "gap" under the first row at y 30, inside the
+  // tabs, and the routes ran through them.
+  const strip: Rect = { left: 94, top: 6, width: 980, height: 85 };
+  const squeezed: Record<string, Rect> = {
+    'w1-webshop': { left: 201, top: 10, width: 99, height: 30 },
+    'w2-webshop': { left: 109, top: 42, width: 101, height: 30 },
+    'w3-webshop': { left: 212, top: 42, width: 101, height: 30 },
+    'w1-api-gateway': { left: 518, top: 10, width: 99, height: 30 },
+    'w2-api-gateway': { left: 407, top: 42, width: 143, height: 32 },
+    'w3-api-gateway': { left: 552, top: 43, width: 101, height: 30 },
+    'w1-notes': { left: 744, top: 20, width: 136, height: 30 },
+    'w1-docs-site': { left: 968, top: 10, width: 99, height: 30 },
+    'w2-docs-site': { left: 870, top: 42, width: 101, height: 30 },
+  };
+  const all = Object.values(squeezed);
+
+  it('makes overlapping spans one row, so no gap is ever inside a tab', () => {
+    const helper = loadLineageHelper();
+    // 10-40 and 20-50 overlap, and 42-74 overlaps 20-50: one row, no gap inside.
+    expect(helper.computeRows(all)).toEqual([{ top: 10, bottom: 74 }]);
+    // Rows that only share a top (the active tab is taller) stay one row, and rows
+    // with a real gap between them stay apart.
+    expect(helper.computeRows([tab(0, 4), tab(130, 4, 120, 32), tab(0, 46)])).toEqual([
+      { top: 4, bottom: 36 },
+      { top: 46, bottom: 76 },
+    ]);
+  });
+
+  it('draws no segment inside a tab, whichever tab is the parent or the child', () => {
+    const helper = loadLineageHelper();
+    const names = Object.keys(squeezed);
+    let drawn = 0;
+    for (const parentName of names) {
+      for (const lane of [0, 1, 2]) {
+        const children = names.filter((n) => n !== parentName).map((n) => ({ id: n, rect: squeezed[n] }));
+        const geom = helper.computeTree({
+          parent: squeezed[parentName],
+          children,
+          strip,
+          tabs: all,
+          lane,
+          laneCount: 3,
+        });
+        for (const route of geom?.routes ?? []) {
+          drawn++;
+          for (let i = 1; i < route.points.length; i++) {
+            for (const r of all) {
+              expect(crossesRect(route.points[i - 1], route.points[i], r), `${parentName} -> ${route.id}`).toBe(false);
+            }
+          }
+        }
+      }
+    }
+    // Some routes still have a clean way (a tab with nothing under it), so the
+    // check above is not vacuous.
+    expect(drawn).toBeGreaterThan(0);
+  });
+
+  it('draws nothing into rows with no gap between them', () => {
+    const helper = loadLineageHelper();
+    // Two rows touching (no row gap at all): the only place a route could run is
+    // through the tabs of the other row.
+    const upper = [tab(0, 4), tab(130, 4)];
+    const lower = [tab(0, 34), tab(130, 34)];
+    const geom = helper.computeTree({
+      parent: upper[0],
+      children: [
+        { id: 'below', rect: lower[1] },
+        { id: 'beside', rect: upper[1] },
+      ],
+      strip: { left: 0, top: 0, width: 600, height: 80 },
+      tabs: [...upper, ...lower],
+    })!;
+    expect(geom.routes).toEqual([]);
+  });
+});
+
 describe('lineage tree geometry: vertical rail', () => {
   const strip: Rect = { left: 100, top: 20, width: 320, height: 320 };
   const parent: Rect = { left: 132, top: 40, width: 260, height: 40 };

test/tab-clusters.test.ts

@@ -171,7 +171,9 @@ describe('tab layouts by case and ledger (app.js)', () => {
       name: box.querySelector('.tab-cluster-name')?.textContent ?? null,
       count: box.querySelector('.tab-cluster-count')?.textContent ?? null,
       single: box.classList.contains('tab-cluster--single'),
-      rows: [...box.querySelectorAll<HTMLElement>('.session-tab')].map((t) => t.dataset.id || `web:${t.dataset.webviewId}`),
+      rows: [...box.querySelectorAll<HTMLElement>('.session-tab')].map(
+        (t) => t.dataset.id || `web:${t.dataset.webviewId}`
+      ),
     }));
 
   beforeEach(() => {
@@ -190,7 +192,9 @@ describe('tab layouts by case and ledger (app.js)', () => {
       { name: null, count: null, single: true, rows: ['web:w1'] },
     ]);
     for (const box of container().querySelectorAll<HTMLElement>(':scope > .tab-cluster:not(.tab-cluster--web)')) {
-      expect(box.getAttribute('style')).toMatch(/^--cluster-color: var\(--session-(blue|green|purple|orange|pink|yellow|red)\)$/);
+      expect(box.getAttribute('style')).toMatch(
+        /^--cluster-color: var\(--session-(blue|green|purple|orange|pink|yellow|red)\)$/
+      );
       expect(box.getAttribute('role')).toBe('presentation');
     }
   });
@@ -261,6 +265,35 @@ describe('tab layouts by case and ledger (app.js)', () => {
     expect(container().classList.contains('tabs-clusters')).toBe(false);
   });
 
+  it('wraps the header strip when a case box wraps inside itself', () => {
+    // A case wider than the strip wraps in its own box and never overflows, so
+    // the measured auto-wrap alone would leave the strip unwrapped, and with it the
+    // lineage routing room unreserved.
+    const app = makeApp();
+    app._fullRenderSessionTabs();
+    Object.assign(app, {
+      _syncLineageGutter: () => {},
+      isSessionSidebarActive: () => false,
+      loadAppSettingsFromStorage: () => ({ tabArrangement: 'case' }),
+      getDefaultSettings: () => ({ tabTwoRows: false, tabOrientation: 'horizontal' }),
+    });
+    const webshop = [...container().querySelectorAll<HTMLElement>('[data-cluster-key="/c/webshop"] > .session-tab')];
+    expect(webshop).toHaveLength(3);
+    const place = (tops: number[]) =>
+      webshop.forEach((el, i) => Object.defineProperty(el, 'offsetTop', { configurable: true, value: tops[i] }));
+    const overflow = CodemanApp.prototype.updateTabOverflowMode;
+
+    place([0, 0, 0]);
+    overflow.call(app);
+    expect(container().classList.contains('tabs-auto-wrap')).toBe(false);
+    expect(app._tabClustersWrapInside(container())).toBe(false);
+
+    place([0, 0, 38]);
+    overflow.call(app);
+    expect(app._tabClustersWrapInside(container())).toBe(true);
+    expect(container().classList.contains('tabs-auto-wrap')).toBe(true);
+  });
+
   it('draws the ledger with the classic markup and one class', () => {
     makeApp('classic')._fullRenderSessionTabs();
     const classic = container().innerHTML;
@@ -279,6 +312,19 @@ describe('tab layouts by case and ledger (static)', () => {
     expect(css).toMatch(/\.session-tabs\.tabs-clusters \.tab-name-case \{\s*display: none;/);
   });
 
+  it('keeps each case box its width on the desktop header strip, so the strip wraps box by box', () => {
+    // Allowed to shrink, every box squeezed and wrapped inside itself at 1440px
+    // (overlapping tab rows, the lineage routes through tabs and labels) and the
+    // strip never overflowed, so it never wrapped.
+    const media = css.indexOf(
+      '@media (min-width: 768px) {\n  .session-tabs-host > .session-tabs.tabs-clusters > .tab-cluster {'
+    );
+    expect(media).toBeGreaterThan(-1);
+    expect(css.slice(media, css.indexOf('}', media))).toContain('flex-shrink: 0;');
+    // Only a case wider than the strip wraps inside its box.
+    expect(css).toMatch(/\.session-tabs-host > \.session-tabs\.tabs-clusters > \.tab-cluster \{[^}]*max-width: 100%;/);
+  });
+
   it('keeps the ledger to the desktop header strip', () => {
     const media = css.indexOf('@media (min-width: 768px) {\n  .session-tabs-host > .session-tabs.tabs-ledger {');
     expect(media).toBeGreaterThan(-1);
@@ -288,7 +334,9 @@ describe('tab layouts by case and ledger (static)', () => {
   });
 
   it('keeps every ledger row one height and makes the active cell stand out', () => {
-    const ledger = css.slice(css.indexOf('@media (min-width: 768px) {\n  .session-tabs-host > .session-tabs.tabs-ledger {'));
+    const ledger = css.slice(
+      css.indexOf('@media (min-width: 768px) {\n  .session-tabs-host > .session-tabs.tabs-ledger {')
+    );
     expect(ledger).toContain('align-items: stretch;');
     expect(ledger).toContain('min-height: 30px;');
     expect(ledger).toMatch(

test/tab-overflow.test.ts

@@ -78,6 +78,22 @@ describe('tab overflow layout policy', () => {
     // A single overflowing tab must not wrap (need at least 2 to form a second row).
     expect(helper.shouldAutoWrapTabs({ ...base, tabCount: 1, scrollWidth: 1400, clientWidth: 760 })).toBe(false);
   });
+
+  it('wraps a strip whose case cluster already wraps inside itself, though nothing overflows', () => {
+    // A case wider than the whole strip is capped at its width and wraps in its
+    // box, so the strip has rows that scrollWidth never shows. Without the wrap,
+    // the lineage routing room (row gap, spine channel) is never reserved.
+    const helper = loadTabOverflowHelper();
+    const fits = { manualTwoRows: false, tabCount: 12, scrollWidth: 800, clientWidth: 800 };
+
+    expect(helper.shouldAutoWrapTabs({ ...fits, deviceType: 'desktop', innerWrap: true })).toBe(true);
+    expect(helper.shouldAutoWrapTabs({ ...fits, deviceType: 'desktop', innerWrap: false })).toBe(false);
+    // The other guards still win.
+    expect(helper.shouldAutoWrapTabs({ ...fits, deviceType: 'tablet', innerWrap: true })).toBe(false);
+    expect(helper.shouldAutoWrapTabs({ ...fits, deviceType: 'desktop', manualTwoRows: true, innerWrap: true })).toBe(
+      false
+    );
+  });
 });
 
 // Issue #257: the phone tab strip scrolls horizontally, so the active tab can