Heat pipe cooling for battery thermal management systems (BTMSs) in electric vehicles (EVs) is growing due to its advantages of high cooling efficiency, compact structure and flexible geometry. Considering the transient conduction, phase change and uncertain thermal conditions in a heat pipe, it is challenging to obtain the dynamic thermal characteristics accurately in such complex heat and mass transfer process. In this paper, a “segmented” thermal resistance model of a heat pipe is proposed based on thermal circuit method. The equivalent conductivities of different segments, viz. the evaporator and condenser of pipe, are used to determine their own thermal parameters and conditions integrated into the thermal model of battery for a complete three-dimensional (3D) computational fluid dynamics (CFD) simulation. The proposed “segmented” model shows more precise than the “non-segmented” model by the comparison of simulated and experimental temperature distribution and variation of an ultra-thin micro heat pipe (UMHP) battery pack, and has less calculation error to obtain dynamic thermal behavior for exact thermal design, management and control of heat pipe BTMSs. Using the “segmented” model, the cooling effect of the UMHP pack with different natural/forced convection and arrangements is predicted, and the results correspond well to the tests. •A “segmented” thermal resistance model of a heat pipe is proposed.•Accuracy of “segmented” model is verified by comparing with “non-segmented” model.•Ultra-thin micro heat pipe(UMHP) is compact and effective for EV battery cooling.•The cooling effect of an UMHP pack with natural/forced convection is evaluated.•The thermal performance of an UMHP pack with different arrangements is compared.