From 0370a3061df5da7fe24dfe1f1513c28ee98f0e5d Mon Sep 17 00:00:00 2001
From: "J. Nick Koston" <nick@home-assistant.io>
Date: Tue, 23 Sep 2025 21:41:48 -0500
Subject: [PATCH] fix

---
 esphome/components/usb_uart/usb_uart.cpp | 7 ++-----
 esphome/components/usb_uart/usb_uart.h   | 4 ++--
 2 files changed, 4 insertions(+), 7 deletions(-)

diff --git a/esphome/components/usb_uart/usb_uart.cpp b/esphome/components/usb_uart/usb_uart.cpp
index a872b37fa2..b485397214 100644
--- a/esphome/components/usb_uart/usb_uart.cpp
+++ b/esphome/components/usb_uart/usb_uart.cpp
@@ -246,11 +246,8 @@ void USBUartComponent::start_input(USBUartChannel *channel) {
       chunk->channel = channel;
 
       // Push to lock-free queue for main loop processing
-      if (!this->usb_data_queue_.push(chunk)) {
-        ESP_LOGW(TAG, "USB data queue full, dropping %u bytes", status.data_len);
-        // Return chunk to pool
-        this->chunk_pool_.release(chunk);
-      }
+      // Push always succeeds because pool size == queue size
+      this->usb_data_queue_.push(chunk);
     }
 
     // Always restart input immediately from USB task
diff --git a/esphome/components/usb_uart/usb_uart.h b/esphome/components/usb_uart/usb_uart.h
index 1389ceeaee..aab36c52b5 100644
--- a/esphome/components/usb_uart/usb_uart.h
+++ b/esphome/components/usb_uart/usb_uart.h
@@ -137,8 +137,8 @@ class USBUartComponent : public usb_host::USBClient {
   LockFreeQueue<UsbDataChunk, USB_DATA_QUEUE_SIZE> usb_data_queue_;
 
   // Pool for allocating data chunks (uses EventPool pattern like BLE)
-  static constexpr int MAX_DATA_CHUNKS = 40;
-  EventPool<UsbDataChunk, MAX_DATA_CHUNKS> chunk_pool_;
+  // MUST be same size as queue to guarantee push always succeeds after allocate
+  EventPool<UsbDataChunk, USB_DATA_QUEUE_SIZE> chunk_pool_;
 
  protected:
   std::vector<USBUartChannel *> channels_{};