diff --git a/lib/hal/HalGPIO.cpp b/lib/hal/HalGPIO.cpp
index 64a251de..ec0176a2 100644
--- a/lib/hal/HalGPIO.cpp
+++ b/lib/hal/HalGPIO.cpp
@@ -7,7 +7,14 @@ void HalGPIO::begin() {
   pinMode(UART0_RXD, INPUT);
 }
 
-void HalGPIO::update() { inputMgr.update(); }
+void HalGPIO::update() {
+  inputMgr.update();
+  const bool connected = isUsbConnected();
+  usbStateChanged = (connected != lastUsbConnected);
+  lastUsbConnected = connected;
+}
+
+bool HalGPIO::wasUsbStateChanged() const { return usbStateChanged; }
 
 bool HalGPIO::isPressed(uint8_t buttonIndex) const { return inputMgr.isPressed(buttonIndex); }
 
diff --git a/lib/hal/HalGPIO.h b/lib/hal/HalGPIO.h
index 09e1fa52..a283ed60 100644
--- a/lib/hal/HalGPIO.h
+++ b/lib/hal/HalGPIO.h
@@ -23,6 +23,9 @@ class HalGPIO {
   InputManager inputMgr;
 #endif
 
+  bool lastUsbConnected = false;
+  bool usbStateChanged = false;
+
  public:
   HalGPIO() = default;
 
@@ -41,6 +44,9 @@ class HalGPIO {
   // Check if USB is connected
   bool isUsbConnected() const;
 
+  // Returns true once per edge (plug or unplug) since the last update()
+  bool wasUsbStateChanged() const;
+
   enum class WakeupReason { PowerButton, AfterFlash, AfterUSBPower, Other };
 
   WakeupReason getWakeupReason() const;
diff --git a/src/components/themes/BaseTheme.cpp b/src/components/themes/BaseTheme.cpp
index fc0a0156..7894aa74 100644
--- a/src/components/themes/BaseTheme.cpp
+++ b/src/components/themes/BaseTheme.cpp
@@ -5,6 +5,7 @@
 #include <HalStorage.h>
 #include <Logging.h>
 
+#include <algorithm>
 #include <cstdint>
 #include <string>
 
@@ -37,7 +38,11 @@ void drawBatteryIcon(const GfxRenderer& renderer, int x, int y, int battWidth, i
   const bool charging = gpio.isUsbConnected();
 
   // The +1 is to round up, so that we always fill at least one pixel
-  constexpr int maxFillWidth = battWidth - 5;
+  const int maxFillWidth = battWidth - 5;
+  const int fillHeight = rectHeight - 4;
+  if (maxFillWidth <= 0 || fillHeight <= 0) {
+    return;
+  }
   int filledWidth = percentage * maxFillWidth / 100 + 1;
   if (filledWidth > maxFillWidth) {
     filledWidth = maxFillWidth;
@@ -46,10 +51,10 @@ void drawBatteryIcon(const GfxRenderer& renderer, int x, int y, int battWidth, i
   // When charging, ensure minimum fill so lightning bolt is fully visible
   constexpr int minFillForBolt = 8;
   if (charging && filledWidth < minFillForBolt) {
-    filledWidth = minFillForBolt;
+    filledWidth = std::min(minFillForBolt, maxFillWidth);
   }
 
-  renderer.fillRect(x + 2, y + 2, filledWidth, rectHeight - 4);
+  renderer.fillRect(x + 2, y + 2, filledWidth, fillHeight);
 
   // Draw lightning bolt when charging (white/inverted on black fill for visibility)
   if (charging) {
diff --git a/src/main.cpp b/src/main.cpp
index 7bd21f37..75bf69c5 100644
--- a/src/main.cpp
+++ b/src/main.cpp
@@ -379,6 +379,12 @@ void loop() {
     return;
   }
 
+  // Refresh the battery icon when USB is plugged or unplugged.
+  // Placed after sleep guards so we never queue a render that won't be processed.
+  if (gpio.wasUsbStateChanged()) {
+    activityManager.requestUpdate();
+  }
+
   const unsigned long activityStartTime = millis();
   activityManager.loop();
   const unsigned long activityDuration = millis() - activityStartTime;