Fix state persistence when popup is closed

- Add 'dismissed' status to prevent dismissed PDFs from reappearing
- Persist PDFs discovered from current tab and recent downloads via background
- Add dismissPDF function that marks PDFs as dismissed instead of removing
- Dismissed PDFs are kept for 7 days for duplicate detection, then cleaned up
- Completed items (sent/canceled) can still be fully removed
- Add addPDF message handler to service worker for popup-discovered PDFs

Co-Authored-By: Claude Opus 4.5 <noreply@anthropic.com>

src/background/service-worker.ts

@@ -11,6 +11,7 @@ import {
   getAllPDFs,
   getPendingPDFs,
   updatePDFStatus,
+  dismissPDF,
   removePDF,
   cleanupOldEntries,
   PDFStatus,
@@ -129,6 +130,19 @@ chrome.runtime.onMessage.addListener((request, sender, sendResponse) => {
     return true;
   }
 
+  // Add a PDF to the queue (from popup discovery)
+  if (request.action === 'addPDF') {
+    addPDF(request.pdf).then(entry => {
+      if (entry) {
+        console.log('[Service Worker] PDF added via message:', entry.filename);
+      }
+      return updateBadge().then(() => entry);
+    }).then(entry => {
+      sendResponse({ entry });
+    });
+    return true;
+  }
+
   // Legacy: Get only actionable PDFs
   if (request.action === 'getPDFQueue') {
     getPendingPDFs().then(entries => {
@@ -148,6 +162,15 @@ chrome.runtime.onMessage.addListener((request, sender, sendResponse) => {
     return true;
   }
 
+  if (request.action === 'dismissPDF') {
+    dismissPDF(request.id).then(() => {
+      return updateBadge();
+    }).then(() => {
+      sendResponse({ success: true });
+    });
+    return true;
+  }
+
   if (request.action === 'removePDF') {
     removePDF(request.id).then(() => {
       return updateBadge();

src/popup/popup.ts

@@ -153,22 +153,20 @@ async function loadPDFQueue() {
   console.log('[Popup] Loading PDF queue...');
 
   // Get all PDFs from background script (including completed ones)
-  const response = await chrome.runtime.sendMessage({ action: 'getAllPDFs' });
+  let response = await chrome.runtime.sendMessage({ action: 'getAllPDFs' });
   pdfQueue = response?.entries || [];
   console.log('[Popup] Got', pdfQueue.length, 'entries from background');
 
-  // Also check current tab for PDF
+  // Check current tab for PDF and add to persistent queue via background
   const currentTabPDF = await checkCurrentTabForPDF();
   if (currentTabPDF) {
-    // Check if already in queue
-    const exists = pdfQueue.some(p => p.url === currentTabPDF.url);
-    if (!exists) {
-      console.log('[Popup] Adding current tab PDF to queue:', currentTabPDF.filename);
-      const entry: PDFQueueEntry = {
-        ...currentTabPDF,
-        status: 'pending'
-      };
-      pdfQueue.unshift(entry);
+    // Add via background service (will check for duplicates/dismissed)
+    const addResult = await chrome.runtime.sendMessage({
+      action: 'addPDF',
+      pdf: currentTabPDF
+    });
+    if (addResult?.entry) {
+      console.log('[Popup] Added current tab PDF to persistent queue:', currentTabPDF.filename);
     }
   }
 
@@ -177,16 +175,19 @@ async function loadPDFQueue() {
     console.log('[Popup] Queue empty, checking recent downloads...');
     const recentPDFs = await checkRecentDownloads();
     for (const pdf of recentPDFs) {
-      const exists = pdfQueue.some(p => p.url === pdf.url);
-      if (!exists) {
-        pdfQueue.push({
-          ...pdf,
-          status: 'pending'
-        });
-      }
+      // Add each PDF via background service (will check for duplicates/dismissed)
+      await chrome.runtime.sendMessage({
+        action: 'addPDF',
+        pdf
+      });
     }
   }
 
+  // Reload queue after potential additions
+  response = await chrome.runtime.sendMessage({ action: 'getAllPDFs' });
+  pdfQueue = response?.entries || [];
+  console.log('[Popup] Final queue count:', pdfQueue.length);
+
   // Render the list
   renderPDFList();
 }
@@ -757,7 +758,17 @@ async function handleRefreshStatus(id: string) {
  * Handle dismiss PDF
  */
 async function handleDismissPDF(id: string) {
-  await chrome.runtime.sendMessage({ action: 'removePDF', id });
+  const pdf = pdfQueue.find(p => p.id === id);
+  if (!pdf) return;
+
+  // For pending/failed/in_basket items, mark as dismissed to prevent re-showing
+  // For completed items (sent/canceled), actually remove from storage
+  if (pdf.status === 'sent' || pdf.status === 'canceled') {
+    await chrome.runtime.sendMessage({ action: 'removePDF', id });
+  } else {
+    await chrome.runtime.sendMessage({ action: 'dismissPDF', id });
+  }
+
   pdfQueue = pdfQueue.filter(p => p.id !== id);
   renderPDFList();
 }

src/utils/pdf-queue.ts

@@ -11,6 +11,7 @@ const STORAGE_KEY = 'pdfQueue';
 const MAX_ENTRIES = 50;
 const SENT_MAX_AGE_MS = 7 * 24 * 60 * 60 * 1000; // 7 days
 const FAILED_MAX_AGE_MS = 24 * 60 * 60 * 1000; // 24 hours
+const DISMISSED_MAX_AGE_MS = 7 * 24 * 60 * 60 * 1000; // 7 days
 
 export type PDFStatus =
   | 'pending'       // Not yet uploaded
@@ -20,7 +21,8 @@ export type PDFStatus =
   | 'ordering'      // Order in progress
   | 'in_production' // PRODUCTION_QUEUE or PRINTING
   | 'sent'          // SENT - terminal
-  | 'canceled';     // CANCELED - terminal
+  | 'canceled'      // CANCELED - terminal
+  | 'dismissed';    // User dismissed, don't show again
 
 export interface PDFQueueEntry extends DetectedPDF {
   status: PDFStatus;
@@ -70,10 +72,10 @@ export async function addPDF(pdf: DetectedPDF): Promise<PDFQueueEntry | null> {
   // Check for duplicate by URL
   const existing = state.entries.find(e => e.url === pdf.url);
   if (existing) {
-    // Skip if already uploaded (in basket, production, or completed)
-    const uploadedStatuses: PDFStatus[] = ['in_basket', 'ordering', 'in_production', 'sent', 'canceled'];
-    if (uploadedStatuses.includes(existing.status)) {
-      console.log('[PDF Queue] PDF already uploaded, skipping:', pdf.filename);
+    // Skip if already processed (uploaded, dismissed, etc.)
+    const processedStatuses: PDFStatus[] = ['in_basket', 'ordering', 'in_production', 'sent', 'canceled', 'dismissed'];
+    if (processedStatuses.includes(existing.status)) {
+      console.log('[PDF Queue] PDF already processed, skipping:', pdf.filename, existing.status);
       return null;
     }
     console.log('[PDF Queue] PDF already in queue:', pdf.filename);
@@ -160,7 +162,24 @@ export async function updatePDFStatus(
 }
 
 /**
- * Remove a PDF from the queue
+ * Dismiss a PDF (mark as dismissed so it won't reappear)
+ */
+export async function dismissPDF(id: string): Promise<void> {
+  const state = await loadQueue();
+  const entry = state.entries.find(e => e.id === id);
+
+  if (!entry) {
+    console.warn('[PDF Queue] PDF not found for dismissal:', id);
+    return;
+  }
+
+  entry.status = 'dismissed';
+  await saveQueue(state);
+  console.log('[PDF Queue] Dismissed PDF:', id);
+}
+
+/**
+ * Remove a PDF from the queue (complete removal, used for cleanup)
  */
 export async function removePDF(id: string): Promise<void> {
   const state = await loadQueue();
@@ -177,11 +196,12 @@ export async function removePDF(id: string): Promise<void> {
 }
 
 /**
- * Get all PDFs for display in popup (all non-terminal statuses + recent terminal)
+ * Get all PDFs for display in popup (excludes dismissed)
  */
 export async function getAllPDFs(): Promise<PDFQueueEntry[]> {
   const state = await loadQueue();
-  return state.entries;
+  // Filter out dismissed entries - they're kept for duplicate detection but not displayed
+  return state.entries.filter(e => e.status !== 'dismissed');
 }
 
 /**
@@ -254,6 +274,14 @@ export async function cleanupOldEntries(): Promise<void> {
       }
     }
 
+    // Remove dismissed entries older than 7 days
+    if (entry.status === 'dismissed') {
+      const age = now - entry.timestamp;
+      if (age > DISMISSED_MAX_AGE_MS) {
+        return false;
+      }
+    }
+
     return true;
   });