Audio speaker with sandwich-structured composite diaphragm

An audio speaker comprising:

• a frame;
• a diaphragm that includes
• an outer shell and an inner shell, each shell having a face portion and an edge portion that is formed to be substantially perpendicular to the face portion, the inner shell being inserted into the outer shell such that at least a part of the edge portion of each shell is in contact with at least a part of the edge portion of the other shell and a space is formed between the face portions of each shell, the face portion of the outer shell being solid and the face portion of the inner shell being perforated, and
• a cellular core that is bonded to the face portion of each shell, the cellular core including a plurality of cells that fill the entire space formed between the face portions of each shell, each of the plurality of cells being filled with air that is in continuous communication with air that is external to the diaphragm through the perforated inner shell;
• a surround that movably couples the diaphragm to the frame;
• a magnetic circuit coupled to the frame, the magnetic circuit having a gap and creating a magnetic field within the gap;
• and
• a voice coil that is coupled to the diaphragm and passing through the gap of the magnetic circuit to move the diaphragm when an electrical current flows in the voice coil.

A method for constructing a diaphragm for an audio speaker, the method comprising:

• forming an outer shell and an inner shell, each shell having a face portion and an edge portion that is formed to be substantially perpendicular to the face portion, the face portion of the outer shell being solid and the face portion of the inner shell being perforated;
• bonding a cellular core to the face portion of the outer shell;
• inserting the inner shell into the outer shell such that at least a part of the edge portion of each shell is in contact with at least a part of the edge portion of the other shell;
• and
• bonding the cellular core to the face portion of the inner shell such that the cellular core creates a plurality of cells that fill the entire space formed between the face portions of each shell, each of the plurality of cells being filled with air that is in continuous communication with air that is external to the diaphragm through the perforated inner shell.