•An unconventional VIP, labeled cavity-core matrix VIP (CCM-VIP) was investigated.•CCM-VIP was composed of glass fiber core encapsulated in Al foil envelope.•Surface cavities on CCM-VIP formed interlocking topology with adjacent mortar.•Bond strength for optimized CCM-VIP increased by about 50% magnitude.•The equivalent thermal conductivity for optimized CCM-VIP was 4.8mW/(mK). Energy efficiency of buildings can be improved by implementing strategies to develop the building envelope components. Thermal insulation of buildings has become vital, to attenuate energy demands for space heating and cooling. Presently vacuum insulation panel (VIP) is regarded as a high performance thermal insulation material. VIP enables efficient insulation solutions in systems such as refrigerators, controlled thermal packages and buildings. For building applications, it is imperative to minimize material defects and to ensure thermal comfort. However, these panels typically use spacers that cause a significant thermal bridge and undesirable gas permeation through spacer hole seal area. This study introduces an unconventional VIP, labeled as cavity-core matrix VIP; solving the aforementioned technical issue related to VIP application in buildings. The cavity-core matrix VIP was composed of glass fiber core material, and laminated aluminum foil envelope material. Owing to interlocking surface topology, bond strength increased by nearly 50% magnitude; considering the limitations specified. The estimated equivalent thermal conductivity of the optimized cavity-core matrix VIP was about 4.8mW/(mK). The preparation processes, thermo-physical properties and challenges of cavity-core matrix VIP were discussed. The concept and exposition examined will enable building engineers and manufacturers to create thermally well performing and structurally adapted VIPs.