The 5% increase is 5% of the base cost of the tech, not the current cost that is based on how many cities you already have. At just your cap the increase is the same, at 21 cities an increase of 5% of the base costs is 2.5% of the current cost. So the calculation is actually more complicated than "does this city make more than 5% of my current bpt?"
T4 base costs are 2480, T4 Leaf techs are 3210. 5% is 120 for T4, 160 for T4L.
The relevant calculation for marginal research benefit is your tech rate, in TURNS. Will the city contribute more science before the tech is researched than it's marginal increase in per-tech cost?
If you have a single 400 bpt city, that's 8 turns per T4L tech (okay, okay, 402). You found your second city, on turn 250. For a T4 leaf tech, your new city raised the cost by 160, to 3370. Now it will take 9 turns to research the tech. OH NOES! But you quickly buy a Depot, Autoplant, and three Routes, sending them to three foreign capitals. You get 15bpt from each, netting 45bpt. Your science rate went up by over 10%. In fact, your estimated turns is now 7.5! Most importantly, over those 8 turns, your new city will contribute 360
, far more than the 160
cost increase.
If you spam late cities, there are two models.
1) They are largely undeveloped, very low pop, and they will have little or no base science - maybe 3-5bpt. But you would use all three TR for Ext, with no incoming routes, so net 40+ bpt is easy.
2) They are more developed, with buildings and tile improvements. You probably use one TR for internal production to pump it up, either incoming or outgoing. But the city itself will have a larger population, in the 4-8 range, and will include some basic buildings, like Clinic, Cytonursery, and Laboratory. That's almost 15 science right there (pop + bldgs) - enough to cover the missing External TR. Add some academies or science-producing resources, and you're far ahead. With still two ExTR, you'll easily get over 40 bpt total from the city, especially considering that building and tile/terrain science is subject to Virtue modifiers.
If 40bpt is a reasonable return on a new late game city, then your marginal science return from the city is negative ONLY IF you are teching faster than 4 turns per T4 LEAF tech. That means 800bpt in an OCC, +5% for each city you own. 6 cities? 800 + 30%, or 1040bpt.
What about cheaper techs, where a fast turns-per-tech means less benefit from your new city? Most T3 techs are 770, T3L 1160. T3.5 is 1160 (Mechatronics, Alien Ethics, Transgenics), with T3.5L at 1820. 1160 per tech means the cost rises 58
for each extra city. It's hard to get 58 science from a spammed city, but 29 isn't so tough. So if you are planning on teching lots of these T3 leaf techs in one turn each (i.e., your science is far OVER 1160bpt), postpone your city spam until afterwards.
Note that for the 770 T3 techs, 5% is 38.5
, and that IS a feasible per-turn-rate with spammed cities. Thus, for all technologies at T3, T2L, or cheaper, spamming cities is ALWAYS worth it.
Obviously, this only applies to science costs. Virtues and Health = YMMV.
tl;dr: Regardless of how many cities you currently have, adding another city can increase your science rate if:
1) it takes you longer than 2 turns to research T3.5 technologies
2) it takes you longer than 3 turns to research T4 technologies
3) it takes you longer than 4 turns to research T4L technologies.