Abstract:
A vehicle charge air cooler having an exhaust gas recirculation mixer integrated into the inlet, inlet manifold, outlet, or outlet manifold takes advantage of the incremental tooling opportunities associated with those components, as well as reducing the number of components and potential leak points in the exhaust gas recirculation system.

Description:
BACKGROUND OF THE INVENTION 
     1.—Field of the Invention 
     This invention relates to the use of a vehicle Charge Air Cooler (CAC) having an integrated Exhaust Gas Recirculation (EGR) mixer. The integrated Exhaust Gas Recirculation mixer is located either at the inlet, at the inlet manifold, at the outlet, or at the outlet manifold of the Charge Air Cooler. The vehicle Charge Air Cooler having an integrated Exhaust Gas Recirculation mixer may be utilized in a vehicle employing a conventional air to coolant Exhaust Gas Recirculation cooler, or may be used as the sole means of Exhaust Gas Recirculation cooling. 
     2.—Description of the Related Art 
     Multiple cylinder internal combustion reciprocating engines used in ground traveling vehicles operate by drawing in ambient intake air, compressing the air, injecting fuel to create a fuel air mixture, igniting the fuel air mixture, extracting work as the heated combustion byproducts expand, and exhausting the combustion byproducts to the surrounding environment. Ignition of the fuel air mixture in an internal combustion reciprocating engine employing the air standard Otto cycle is achieved by means of a spark plug. Internal combustion reciprocating engines employing the air standard Diesel cycle achieve auto-ignition due to the heat of compression of the fuel air mixture. In order to improve performance and operating efficiency, internal combustion reciprocating engines of both the air standard Otto cycle type and the air standard Diesel cycle type commonly utilize a turbocharger. The turbocharger extracts additional work energy from the exhaust gases of the internal combustion reciprocating engine by means of a turbine through which the exhaust gases are made to flow. The turbocharger is typically mounted directly to the exhaust manifold of the internal combustion reciprocating engine in close-coupled proximity to the exhaust outlets for efficient operation of the turbine. The extracted mechanical energy drives a compressor, which compressor increases the pressure of the ambient air drawn into the internal combustion reciprocating engine. 
     Due to the compression of the ambient intake air associated with the use of a turbocharger, and the resulting increase in temperature thereof, ground traveling vehicles commonly utilize an air to air heat exchanger, which is referred to as a Charge Air Cooler (CAC). The Charge Air Cooler is located separately from and forward of the internal combustion reciprocating engine. The intake air is conducted from the outlet of the turbocharger to the inlet of the Charge Air Cooler by a pipe or conduit, which pipe or conduit is connected to both the turbocharger and to the Charge Air Cooler by flexible rubber cuffs or hoses. In this way, relative movement between the internal combustion reciprocating engine and the Charge Air Cooler is accommodated. Another pipe or conduit conducts the compressed and cooled intake air from the outlet of the Charge Air Cooler to the intake manifold of the internal combustion reciprocating engine. The Charge Air Cooler itself is generally constructed in such a way that there is an inlet manifold and an outlet manifold. The inlet manifold and the outlet manifold of the Charge Air Cooler are connected by smaller cooling passages, which smaller cooling passages are separated by a distance sufficient for the passage of external cooling air therebetween. The inlet manifold is provided with an inlet opening to which the aforementioned pipe from the turbocharger is connected. The outlet manifold is in the same way provided with an outlet opening to which the aforementioned pipe to the intake manifold of the internal combustion reciprocating engine is connected. 
     The combustion of the fuel air mixture in an internal combustion reciprocating engine results in combustion byproducts, as noted previously. These byproducts primarily consist of carbon dioxide and water vapor. However, there are myriad other chemical constituents, such as hydrocarbons and oxides of nitrogen. Many of these are undesirable from an environmental standpoint, and therefore measures are taken to reduce their formation and emission. A commonly employed method to reduce internal combustion reciprocating engine emissions is Exhaust Gas Recirculation (EGR). A typical embodiment of Exhaust Gas Recirculation involves a pipe that conducts a portion of the exhaust gases from the exhaust manifold to a mixer pipe located between the Charge Air Cooler outlet and the intake manifold of the internal combustion reciprocating engine. A valve may or may not be employed to control the amount of exhaust gas that is recirculated, and the conditions under which the exhaust gas is allowed to do so. Due to the fact that the exhaust gases are under backpressure prior to their further expansion in the turbine of the turbocharger, Exhaust Gas Recirculation may operate passively, requiring no pump. Often the mixer pipe that is utilized incorporates a venturi to increase the flow of exhaust gas from the exhaust manifold to the intake manifold. Some advanced Exhaust Gas Recirculation systems utilize a turbocharger with variable geometry turbine blades to artificially increase the exhaust gas backpressure in order to further increase the flow of exhaust gas from the exhaust manifold to the intake manifold. 
     Exhaust gases and combustion byproducts leaving the internal combustion reciprocating engine cylinders do so at extremely high temperatures. Therefore, it is common to provide a gas to liquid heat exchanger, which transfers some of the heat from the exhaust gas to the engine coolant, prior to the introduction of the exhaust gas to the intake air at the exhaust gas recirculation mixer. It is also known to configure the system such that the mixer is located between the turbocharger intake air outlet and the Charge Air Cooler inlet. An example of a system configured in this way may be found in U.S. Pat. No. 6,786,210. It is also known, as in U.S. Pat. No. 6,786,210, to provide a bypass circuit within the Charge Air Cooler, in order to prevent condensation of corrosive combustion byproducts within the Charge Air Cooler under certain operating conditions. 
     SUMMARY OF THE INVENTION 
     In each of the prior art embodiments, a separate Exhaust Gas Recirculation mixer has been utilized. Commonly, the mixer exists as a separate cast pipe, which is attached directly to the intake manifold of the internal combustion reciprocating engine. As shown in U.S. Pat. No. 6,786,210, the mixer may be integrated with, or take the place of, the pipe or conduit that would connect the outlet of the turbocharger compressor to the inlet of the Charge Air Cooler. In both prior art embodiments, the Exhaust Gas Recirculation mixer constituted an additional and costly manufactured component, requiring additional installation, often complex underhood piping, and subjecting the intake system of the internal combustion reciprocating engine to an increased number of potential leak points. 
     The present invention takes advantage of the unique incremental tooling opportunities associated with the inlet, inlet manifold, outlet, and outlet manifold of the Charge Air Cooler by incorporating the Exhaust Gas Recirculation mixer directly into one of these components of the Charge Air Cooler. Specifically, the Exhaust Gas Recirculation mixer may be integrated into the outlet or outlet manifold of the Charge Air Cooler and used in conjunction with a conventional exhaust gas to engine coolant heat exchanger, or the Exhaust Gas Recirculation mixer may be integrated into the inlet or inlet manifold of the Charge Air Cooler and used without a conventional exhaust gas to engine coolant heat exchanger. Further, contrary to the teachings of the prior art, the Exhaust Gas Recirculation mixer may be integrated into the inlet or inlet manifold of the Charge Air Cooler and used in conjunction with a conventional exhaust gas to engine coolant heat exchanger. In such configuration the Charge Air Cooler may rely upon stainless steel or other corrosion resistant metal alloy construction to withstand, or a bypass circuit to prevent, condensation of corrosive combustion byproducts. 
     The present invention may be used in conjunction with an Exhaust Gas Recirculation control valve located in the exhaust manifold of the engine, or it may incorporate an Exhaust Gas Recirculation control valve into the integrated Exhaust Gas Recirculation mixer. The integrated Exhaust Gas Recirculation mixer in the Charge Air Cooler inlet, inlet manifold, outlet, or outlet manifold may incorporate a venturi, or it may rely instead on the backpressure of the of the exhaust gas prior to expansion in the turbocharger turbine to provide the necessary flow. Whether used in the inlet, inlet manifold, outlet, or the outlet manifold of the Charge Air Cooler, with or without a conventional exhaust gas to engine coolant heat exchanger, or with or without an Exhaust Gas Recirculation control valve, the present invention simplifies the process of manufacturing vehicles having an Exhaust Gas Recirculation mixer. The overall cost of the vehicle is reduced, as the mixer as a separate component is eliminated. Routing flexibility is further improved, which routing flexibility represents an important consideration in the congested underhood environment. The integrated Exhaust Gas Recirculation mixer may be cast into or stamped into the Charge Air Cooler inlet, inlet manifold, outlet, or outlet manifold. Alternately, it may be a welded assembly. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG.  1 —Prior art engine intake system with Charge Air Cooler, Exhaust Gas Recirculation, and Exhaust Gas Recirculation mixer. 
       FIG.  2 —Prior art engine intake system with Charge Air Cooler, Exhaust Gas Recirculation, and Exhaust Gas Recirculation mixer, with the Exhaust Gas Recirculation mixer located upstream from the Charge Air Cooler. 
       FIG.  3 —A view of a first embodiment of the present invention. 
       FIG.  4 —A view of a second embodiment of the present invention. 
       FIG.  5 —A view of a third embodiment of the present invention. 
       FIG.  6 —A view of a fourth embodiment of the present invention. 
       FIG.  7 —A view of a fifth embodiment of the present invention. 
         FIG. 7   a —A view of a sixth embodiment of the present invention. 
       FIG.  8 —A view of a seventh embodiment of the present invention. 
         FIG. 8   a —A view of an eighth embodiment of the present invention. 
       FIG.  9 —A view of a ninth embodiment of the present invention. 
         FIG. 9   a —A view of a tenth embodiment of the present invention. 
       FIG.  10 —A view of an eleventh embodiment of the present invention. 
         FIG. 10   a —A view of a twelfth embodiment of the present invention. 
         FIG. 10   b —A view of a thirteenth embodiment of the present invention. 
         FIG. 10   c —A view of a fourteenth embodiment of the present invention. 
       FIG.  11 —A view of a fifteenth embodiment of the present invention. 
       FIG.  12 —A view of a sixteenth embodiment of the present invention. 
     
    
    
     DESCRIPTION OF THE INVENTION 
       FIG. 1  shows an engine  102  having a charge air cooler  106  and a prior art exhaust gas recirculation system  115 . The engine  102  is provided with an engine intake manifold  103  and an engine exhaust manifold  104 , to which engine exhaust manifold  104  is attached a turbocharger  105 . The turbocharger  105  functions to extract mechanical energy from the exhaust  201  produced by the engine  102 , and utilize the mechanical energy to compress the intake air  200 , which intake air  200  is conveyed to the charge air cooler  106  by the turbo to charge air cooler pipe  111 . The intake air  200  enters the charge air cooler  106  at the charge air cooler inlet  109 , and is distributed evenly across the charge air cooler  106  by use of a charge air cooler inlet manifold  107 . As the intake air  200  exits the charge air cooler  106 , it is collected in the charge air cooler outlet manifold  108 , before exiting through the charge air cooler outlet  110 . The intake air  200  is then conveyed to an exhaust gas recirculation mixer  119  by a charge air cooler to intake pipe  112 . The exhaust gas recirculation mixer  119  is typically attached directly to the engine intake manifold  103 , and incorporates a venturi  120 . The exhaust gas recirculation system  115 , then, is provided with an exhaust gas recirculation pipe  116 , an exhaust gas recirculation control valve  117 , an exhaust gas recirculation gas to coolant heat exchanger  118 , and the aforementioned exhaust gas recirculation mixer  119 . Some of the exhaust gas  201  produced by the engine  102  is allowed to exit the engine exhaust manifold  104  prior to the turbocharger  105  by the exhaust gas recirculation control valve  117 , at which point it enters the exhaust gas recirculation gas to coolant heat exchanger  118 . Having been reduced in temperature, the exhaust gas  201  is then conveyed to the exhaust gas recirculation mixer  119  by means of the exhaust gas recirculation pipe  116 . The exhaust gas  201  is drawn into the exhaust gas recirculation mixer  119 , at least partially by the venturi  120 , wherein the exhaust gas  201  mixes with the intake air  200 . 
       FIG. 2  shows an engine  102  having a charge air cooler  106  and a prior art exhaust gas recirculation system  115 , similar to the engine  102  shown in  FIG. 1 . The engine  102  in  FIG. 2  is again provided with an engine intake manifold  103  and an engine exhaust manifold  104 , to which engine exhaust manifold  104  is attached a turbocharger  105 . Intake air  200  flows directly from the turbocharger  105  into an exhaust gas recirculation mixer  119 , which exhaust gas recirculation mixer  119  is located upstream from the charge air cooler  106 , and takes the place of the turbo to charge air cooler pipe  111  (not shown). Some of the exhaust gas  201  produced by the engine  102  is allowed to exit the engine exhaust manifold  104  prior to the turbocharger  105  by the exhaust gas recirculation control valve  117 . The exhaust gas  201  again passes through an exhaust gas recirculation gas to coolant heat exchanger  118 , through the exhaust gas recirculation pipe  116 , and to the exhaust gas recirculation mixer  119 , which exhaust gas recirculation mixer  119  may incorporate a venturi  120 . After mixing, the intake and exhaust air mix  202  enters the charge air cooler  106  at the charge air cooler inlet  109 , and is distributed evenly across the charge air cooler  106  by use of the charge air cooler inlet manifold  107 . As the intake and exhaust air mix  202  exits the charge air cooler  106 , it is collected in the charge air cooler outlet manifold  108 , before exiting through the charge air cooler outlet  110 . The intake and exhaust air mix  202  is then conveyed to the engine intake manifold  103  by the charge air cooler to intake pipe  112 . 
       FIG. 3  shows an embodiment of the present invention, specifically a charge air cooler  106 , similar to the charge air coolers  106  shown in  FIGS. 1 and 2 , except that the charge air cooler  106  shown in  FIG. 3  is oriented vertically. The vertical orientation of the charge air cooler  106  shown in  FIG. 3  is of no consequence to the present invention. The charge air cooler  106  is provided with an inlet  109 , an inlet manifold  107 , an outlet manifold  108 , and an outlet  110 . The inlet manifold  107  is further provided with an integrated internal exhaust gas recirculation mixer  121 . Intake air  200  enters the inlet manifold  107  at the inlet  109 , and recirculation exhaust  201  enters the inlet manifold  107  at the integrated internal exhaust gas recirculation mixer  121 . Mixed intake and exhaust air  202  travels through the charge air cooler  106  to be reduced in temperature, passes through the outlet manifold  108 , and exits at the outlet  110 . 
       FIG. 4  shows a charge air cooler  106 , similar to the charge air cooler  106  shown in  FIG. 3 . The charge air cooler  106  shown in  FIG. 4  is again provided with an inlet  109 , an inlet manifold  107 , an outlet manifold  108 , and an outlet  110 . The inlet  109  is further provided with an integrated exhaust gas recirculation mixer  122 , which integrated exhaust gas recirculation mixer  122  is external to the inlet manifold  107 . Intake air  200  enters the inlet  109 , and recirculation exhaust  201  enters the inlet  109  at the integrated exhaust gas recirculation mixer  122 . Mixed intake and exhaust air  202  travels into the inlet manifold  107 , through the charge air cooler  106  to be reduced in temperature, through the outlet manifold  108 , and exits at the outlet  110 . 
       FIG. 5  shows a charge air cooler  106 , similar to the charge air coolers  106  shown in  FIGS. 3 and 4 . The charge air cooler  106  is provided with an inlet  109 , an inlet manifold  107 , an outlet manifold  108 , and an outlet  110 . The outlet manifold  108  is further provided with an integrated internal exhaust gas recirculation mixer  123 . Intake air  200  enters the inlet manifold  107  at the inlet  109 , travels through the charge air cooler  106  to be reduced in temperature, and enters the outlet manifold  108 . Recirculation exhaust  201  also enters the outlet manifold  108 , doing so at the integrated internal exhaust gas recirculation mixer  123 . Mixed intake and exhaust air  202  then exits the outlet manifold  108  at the outlet  110 . 
       FIG. 6  shows a charge air cooler  106 , similar to the charge air coolers  106  shown in  FIGS. 3 ,  4 , and  5 . The charge air cooler  106  shown in  FIG. 6  is again provided with an inlet  109 , an inlet manifold  107 , an outlet manifold  108 , and an outlet  110 . The outlet  110  is further provided with an integrated exhaust gas recirculation mixer  124 , which integrated exhaust gas recirculation mixer  124  is external to the outlet manifold  108 . Intake air  200  enters the inlet  109 , passes through the inlet manifold  107 , through the charge air cooler  106 , and through the outlet manifold  108 . At the outlet  110 , recirculation exhaust  201  enters through the integrated exhaust gas recirculation mixer  124 . Mixed intake and exhaust air  202  then exits the outlet  110 . 
       FIG. 7  shows an engine  102  having a charge air cooler  106  and an embodiment of the present invention, specifically an exhaust gas recirculation system  115  utilizing an integrated exhaust gas recirculation mixer  122  integrated into the charge air cooler inlet  109 . The engine  102  shown in  FIG. 7  is provided with an engine intake manifold  103  and an engine exhaust manifold  104 , to which engine exhaust manifold  104  is attached a turbocharger  105 . Intake air  200  is conveyed from the turbocharger  105  to the charge air cooler inlet  109  by the turbo to charge air cooler pipe  111 . Some of the exhaust gas  201  produced by the engine  102  is allowed to exit the engine exhaust manifold  104  prior to the turbocharger  105  by the exhaust gas recirculation control valve  117 . The exhaust gas  201  travels through the exhaust gas recirculation pipe  116 , and enters the charge air cooler inlet  109  at the integrated exhaust gas recirculation mixer  122 . Mixed intake and exhaust air  202  then travels through the charge air cooler inlet manifold  107 , through the charge air cooler  106 , through the charge air cooler outlet manifold  108 , and exits through the charge air cooler outlet  110 . The mixed intake and exhaust air  202  is then conducted to the engine intake manifold  103  by the charge air cooler to intake pipe  112 . 
       FIG. 7   a  shows an engine  102  having a charge air cooler  106  and an embodiment of the present invention, specifically an exhaust gas recirculation system  115  utilizing an integrated internal exhaust gas recirculation mixer  121  integrated into the charge air cooler inlet manifold  107 . The engine  102  shown in  FIG. 7   a  is provided with an engine intake manifold  103  and an engine exhaust manifold  104 , to which engine exhaust manifold  104  is attached a turbocharger  105 . Intake air  200  is conveyed from the turbocharger  105  to the charge air cooler inlet  109  by the turbo to charge air cooler pipe  111 . From the charge air cooler inlet  109 , the intake air  200  enters the charge air cooler inlet manifold  107 . Some of the exhaust gas  201  produced by the engine  102  is allowed to exit the engine exhaust manifold  104  prior to the turbocharger  105  by the exhaust gas recirculation control valve  117 . The exhaust gas  201  travels through the exhaust gas recirculation pipe  116 , and enters the charge air cooler inlet manifold  107  at the integrated internal exhaust gas recirculation mixer  121 . Mixed intake and exhaust air  202  then travels through the charge air cooler  106 , through the charge air cooler outlet manifold  108 , and exits through the charge air cooler outlet  110 . The mixed intake and exhaust air  202  is then conducted to the engine intake manifold  103  by the charge air cooler to intake pipe  112 . 
       FIG. 8  shows an engine  102  having a charge air cooler  106  and an embodiment of the present invention, specifically an exhaust gas recirculation system  115  utilizing an integrated exhaust gas recirculation mixer  122  integrated into the charge air cooler inlet  109 . The engine  102  shown in  FIG. 8  is provided with an engine intake manifold  103  and an engine exhaust manifold  104 , to which engine exhaust manifold  104  is attached a turbocharger  105 . Intake air  200  is conveyed from the turbocharger  105  to the charge air cooler inlet  109  by the turbo to charge air cooler pipe  111 . Some of the exhaust gas  201  produced by the engine  102  is allowed to exit the engine exhaust manifold  104  prior to the turbocharger  105  by the exhaust gas recirculation control valve  117 . The exhaust gas  201  travels through the exhaust gas recirculation gas to coolant heat exchanger  118 , through the exhaust gas recirculation pipe  116 , and enters the charge air cooler inlet  109  at the integrated exhaust gas recirculation mixer  122 . Mixed intake and exhaust air  202  then travels through the charge air cooler inlet manifold  107 , through the charge air cooler  106 , through the charge air cooler outlet manifold  108 , and exits through the charge air cooler outlet  110 . The mixed intake and exhaust air  202  is then conducted to the engine intake manifold  103  by the charge air cooler to intake pipe  112 . 
       FIG. 8   a  shows an engine  102  having a charge air cooler  106  and an embodiment of the present invention, specifically an exhaust gas recirculation system  115  utilizing an integrated internal exhaust gas recirculation mixer  121  integrated into the charge air cooler inlet manifold  107 . The engine  102  shown in  FIG. 8   a  is provided with an engine intake manifold  103  and an engine exhaust manifold  104 , to which engine exhaust manifold  104  is attached a turbocharger  105 . Intake air  200  is conveyed from the turbocharger  105  to the charge air cooler inlet  109  by the turbo to charge air cooler pipe  111 . From the charge air cooler inlet  109 , the intake air  200  enters the charge air cooler inlet manifold  107 . Some of the exhaust gas  201  produced by the engine  102  is allowed to exit the engine exhaust manifold  104  prior to the turbocharger  105  by the exhaust gas recirculation control valve  117 . The exhaust gas  201  travels through the exhaust gas recirculation gas to coolant heat exchanger  118 , through the exhaust gas recirculation pipe  116 , and enters the charge air cooler inlet manifold  107  at the integrated internal exhaust gas recirculation mixer  121 . Mixed intake and exhaust air  202  then travels through the charge air cooler  106 , through the charge air cooler outlet manifold  108 , and exits through the charge air cooler outlet  110 . The mixed intake and exhaust air  202  is then conducted to the engine intake manifold  103  by the charge air cooler to intake pipe  112 . 
       FIG. 9  shows an engine  102  having a charge air cooler  106  and an embodiment of the present invention, specifically an exhaust gas recirculation system  115  utilizing an integrated exhaust gas recirculation mixer  124  integrated into the charge air cooler outlet  110 . The engine  102  shown in  FIG. 9  is provided with an engine intake manifold  103  and an engine exhaust manifold  104 , to which engine exhaust manifold  104  is attached a turbocharger  105 . Intake air  200  is conveyed from the turbocharger  105  to the charge air cooler inlet  109  by the turbo to charge air cooler pipe  111 . The intake air  200  then travels through the charge air cooler inlet manifold  107 , through the charge air cooler  106 , through the charge air cooler outlet manifold  108 , and exits through the charge air cooler outlet  110 . Some of the exhaust gas  201  produced by the engine  102  is allowed to exit the engine exhaust manifold  104  prior to the turbocharger  105  by the exhaust gas recirculation control valve  117 . The exhaust gas  201  travels through the exhaust gas recirculation gas to coolant heat exchanger  118 , through the exhaust gas recirculation pipe  116 , and enters the charge air cooler outlet  110  at the integrated exhaust gas recirculation mixer  124 . The mixed intake and exhaust air  202  is then conducted to the engine intake manifold  103  by the charge air cooler to intake pipe  112 . 
       FIG. 9   a  shows an engine  102  having a charge air cooler  106  and an embodiment of the present invention, specifically an exhaust gas recirculation system  115  utilizing an integrated exhaust gas recirculation mixer  123  integrated into the charge air cooler outlet manifold  108 . The engine  102  shown in  FIG. 9   a  is provided with an engine intake manifold  103  and an engine exhaust manifold  104 , to which engine exhaust manifold  104  is attached a turbocharger  105 . Intake air  200  is conveyed from the turbocharger  105  to the charge air cooler inlet  109  by the turbo to charge air cooler pipe  111 . The intake air  200  then travels through the charge air cooler inlet manifold  107 , through the charge air cooler  106 , and into the charge air cooler outlet manifold  108 . Some of the exhaust gas  201  produced by the engine  102  is allowed to exit the engine exhaust manifold  104  prior to the turbocharger  105  by the exhaust gas recirculation control valve  117 . The exhaust gas  201  travels through the exhaust gas recirculation gas to coolant heat exchanger  118 , through the exhaust gas recirculation pipe  116 , and enters the charge air cooler outlet manifold  108  at the integrated exhaust gas recirculation mixer  123 . The mixed intake and exhaust air  202  then exits through the charge air cooler outlet  110 , and is conducted to the engine intake manifold  103  by the charge air cooler to intake pipe  112 . 
       FIG. 10  shows an engine  102  having a charge air cooler  106  and an embodiment of the present invention, specifically an exhaust gas recirculation system  115  utilizing an integrated exhaust gas recirculation mixer  122  integrated into the charge air cooler inlet  109 , an exhaust gas recirculation charge air cooler bypass pipe  125 , and another integrated exhaust gas recirculation mixer  124  integrated into the charge air cooler outlet  110 . The engine  102  shown in  FIG. 10  is provided with an engine intake manifold  103  and an engine exhaust manifold  104 , to which engine exhaust manifold  104  is attached a turbocharger  105 . Intake air  200  is conveyed from the turbocharger  105  to the charge air cooler inlet  109  by the turbo to charge air cooler pipe  111 . Some of the exhaust gas  201  produced by the engine  102  is allowed to exit the engine exhaust manifold  104  prior to the turbocharger  105  by the exhaust gas recirculation control valve  117 . The exhaust gas  201  travels through the exhaust gas recirculation gas to coolant heat exchanger  118 , through the exhaust gas recirculation pipe  116 , to an exhaust gas recirculation charge air cooler bypass valve  126 . From the exhaust gas recirculation charge air cooler bypass valve  126 , the exhaust gas  201  may be directed to the integrated exhaust gas recirculation mixer  122  at the charge air cooler inlet  109 , or the exhaust gas  201  may be directed to travel through the exhaust gas recirculation charge air cooler bypass pipe  125  to the integrated exhaust gas recirculation mixer  124  at the charge air cooler outlet  110 , depending on the operating conditions of the engine  102 . If the exhaust gas  201  is directed to the charge air cooler inlet  109 , the mixed intake and exhaust air  202  then travels through the charge air cooler inlet manifold  107 , through the charge air cooler  106 , through the charge air cooler outlet manifold  108 , and exits through the charge air cooler outlet  110 . In both cases, the mixed intake and exhaust air  202  is then conducted to the engine intake manifold  103  by the charge air cooler to intake pipe  112 . 
       FIG. 10   a  shows an engine  102  having a charge air cooler  106  and an embodiment of the present invention, specifically an exhaust gas recirculation system  115  utilizing an integrated internal exhaust gas recirculation mixer  121  integrated into the charge air cooler inlet manifold  107 , an exhaust gas recirculation charge air cooler bypass pipe  125 , and another integrated exhaust gas recirculation mixer  123  integrated into the charge air cooler outlet manifold  108 . The engine  102  shown in  FIG. 10   a  is provided with an engine intake manifold  103  and an engine exhaust manifold  104 , to which engine exhaust manifold  104  is attached a turbocharger  105 . Intake air  200  is conveyed from the turbocharger  105  to the charge air cooler inlet  109  by the turbo to charge air cooler pipe  111 . From the charge air cooler inlet  109 , the intake air  200  enters the charge air cooler inlet manifold  107 . Some of the exhaust gas  201  produced by the engine  102  is allowed to exit the engine exhaust manifold  104  prior to the turbocharger  105  by the exhaust gas recirculation control valve  117 . The exhaust gas  201  travels through the exhaust gas recirculation gas to coolant heat exchanger  118 , through the exhaust gas recirculation pipe  116 , to an exhaust gas recirculation charge air cooler bypass valve  126 . From the exhaust gas recirculation charge air cooler bypass valve  126 , the exhaust gas  201  may be directed to the integrated exhaust gas recirculation mixer  121  at the charge air cooler inlet manifold  107 , or the exhaust gas  201  may be directed to travel through the exhaust gas recirculation charge air cooler bypass pipe  125  to the integrated exhaust gas recirculation mixer  123  at the charge air cooler outlet manifold  108 , depending on the operating conditions of the engine  102 . If the exhaust gas  201  is directed to the charge air cooler inlet manifold  107 , the mixed intake and exhaust air  202  then travels through the charge air cooler  106 , and enters the charge air cooler outlet manifold  108 . In both cases, the mixed intake and exhaust air  202  then exits the charge air cooler  106  at the charge air cooler outlet  110 , and is then conducted to the engine intake manifold  103  by the charge air cooler to intake pipe  112 . 
       FIG. 10   b  shows an engine  102  having a charge air cooler  106  and an embodiment of the present invention, specifically an exhaust gas recirculation system  115  utilizing an integrated exhaust gas recirculation mixer  122  integrated into the charge air cooler inlet  109 , an exhaust gas recirculation charge air cooler bypass pipe  125 , and another integrated exhaust gas recirculation mixer  123  integrated into the charge air cooler outlet manifold  108 . The engine  102  shown in  FIG. 10   b  is provided with an engine intake manifold  103  and an engine exhaust manifold  104 , to which engine exhaust manifold  104  is attached a turbocharger  105 . Intake air  200  is conveyed from the turbocharger  105  to the charge air cooler inlet  109  by the turbo to charge air cooler pipe  111 . Some of the exhaust gas  201  produced by the engine  102  is allowed to exit the engine exhaust manifold  104  prior to the turbocharger  105  by the exhaust gas recirculation control valve  117 . The exhaust gas  201  travels through the exhaust gas recirculation gas to coolant heat exchanger  118 , through the exhaust gas recirculation pipe  116 , to an exhaust gas recirculation charge air cooler bypass valve  126 . From the exhaust gas recirculation charge air cooler bypass valve  126 , the exhaust gas  201  may be directed to the integrated exhaust gas recirculation mixer  122  at the charge air cooler inlet  109 , or the exhaust gas  201  may be directed to travel through the exhaust gas recirculation charge air cooler bypass pipe  125  to the integrated exhaust gas recirculation mixer  123  at the charge air cooler outlet manifold  108 , depending on the operating conditions of the engine  102 . If the exhaust gas  201  is directed to the charge air cooler inlet  109 , the mixed intake and exhaust air  202  then travels through the charge air cooler inlet manifold  107 , through the charge air cooler  106 , to the charge air cooler outlet manifold  108 . In both cases, the mixed intake and exhaust air  202  then exits the charge air cooler  106  through the charge air cooler outlet  110 , and is then conducted to the engine intake manifold  103  by the charge air cooler to intake pipe  112 . 
       FIG. 10   c  shows an engine  102  having a charge air cooler  106  and an embodiment of the present invention, specifically an exhaust gas recirculation system  115  utilizing an integrated internal exhaust gas recirculation mixer  121  integrated into the charge air cooler inlet manifold  107 , an exhaust gas recirculation charge air cooler bypass pipe  125 , and another integrated exhaust gas recirculation mixer  124  integrated into the charge air cooler outlet  110 . The engine  102  shown in  FIG. 10   c  is provided with an engine intake manifold  103  and an engine exhaust manifold  104 , to which engine exhaust manifold  104  is attached a turbocharger  105 . Intake air  200  is conveyed from the turbocharger  105  to the charge air cooler inlet  109  by the turbo to charge air cooler pipe  111 . From the charge air cooler inlet  109 , the intake air  200  enters the charge air cooler inlet manifold  107 . Some of the exhaust gas  201  produced by the engine  102  is allowed to exit the engine exhaust manifold  104  prior to the turbocharger  105  by the exhaust gas recirculation control valve  117 . The exhaust gas  201  travels through the exhaust gas recirculation gas to coolant heat exchanger  118 , through the exhaust gas recirculation pipe  116 , to an exhaust gas recirculation charge air cooler bypass valve  126 . From the exhaust gas recirculation charge air cooler bypass valve  126 , the exhaust gas  201  may be directed to the integrated exhaust gas recirculation mixer  121  at the charge air cooler inlet manifold  107 , or the exhaust gas  201  may be directed to travel through the exhaust gas recirculation charge air cooler bypass pipe  125  to the integrated exhaust gas recirculation mixer  124  at the charge air cooler outlet  110 , depending on the operating conditions of the engine  102 . If the exhaust gas  201  is directed to the charge air cooler inlet manifold  107 , the mixed intake and exhaust air  202  then travels through the charge air cooler  106 , through the charge air cooler outlet manifold  108 , to the charge air cooler outlet  110 . In both cases, the mixed intake and exhaust air  202  is then conducted to the engine intake manifold  103  by the charge air cooler to intake pipe  112 . 
       FIG. 11  shows an engine  102  having a charge air cooler  106  and an embodiment of the present invention, specifically an exhaust gas recirculation system  115  utilizing an integrated exhaust gas recirculation mixer  122  and a venturi  120  integrated into the charge air cooler inlet  109 . The engine  102  shown in  FIG. 11  is provided with an engine intake manifold  103  and an engine exhaust manifold  104 , to which engine exhaust manifold  104  is attached a turbocharger  105 . Intake air  200  is conveyed from the turbocharger  105  to the charge air cooler inlet  109  by the turbo to charge air cooler pipe  111 . Some of the exhaust gas  201  produced by the engine  102  is allowed to exit the engine exhaust manifold  104  prior to the turbocharger  105  by the exhaust gas recirculation control valve  117 . The exhaust gas  201  travels through the exhaust gas recirculation pipe  116 , and enters the venturi  120  of the charge air cooler inlet  109  at the integrated exhaust gas recirculation mixer  122 . Mixed intake and exhaust air  202  then travels through the charge air cooler inlet manifold  107 , through the charge air cooler  106 , through the charge air cooler outlet manifold  108 , and exits through the charge air cooler outlet  110 . The mixed intake and exhaust air  202  is then conducted to the engine intake manifold  103  by the charge air cooler to intake pipe  112 . 
       FIG. 12  shows an engine  102  having a charge air cooler  106  and an embodiment of the present invention, specifically an exhaust gas recirculation system  115  utilizing an integrated exhaust gas recirculation mixer  122  and an exhaust gas recirculation control valve  117  integrated into the charge air cooler inlet  109 . The engine  102  shown in  FIG. 12  is provided with an engine intake manifold  103  and an engine exhaust manifold  104 , to which engine exhaust manifold  104  is attached a turbocharger  105 . Intake air  200  is conveyed from the turbocharger  105  to the charge air cooler inlet  109  by the turbo to charge air cooler pipe  111 . Some of the exhaust gas  201  produced by the engine  102  is allowed to exit the engine exhaust manifold  104  prior to the turbocharger  105 . The exhaust gas  201  travels through the exhaust gas recirculation pipe  116 , and is allowed to enter the charge air cooler inlet  109  at the integrated exhaust gas recirculation mixer  122  by the exhaust gas recirculation control valve  117 , depending upon the operating conditions of the engine  102 . Mixed intake and exhaust air  202  then travels through the charge air cooler inlet manifold  107 , through the charge air cooler  106 , through the charge air cooler outlet manifold  108 , and exits through the charge air cooler outlet  110 . The mixed intake and exhaust air  202  is then conducted to the engine intake manifold  103  by the charge air cooler to intake pipe  112 . 
     Other permutations of the invention are possible without departing from the teachings disclosed herein, provided that the function of the invention is to integrate a vehicle exhaust gas recirculation mixer into the inlet, inlet manifold, outlet, or outlet manifold of a vehicle charge air cooler. Other advantages to a vehicle equipped with a vehicle charge air cooler with an integrated exhaust gas recirculation mixer may also be inherent in the invention, without having been described above.