Patent ID: 8677982

Claim:
An air intake tract delivering combustion air from a turbocharger to an engine, comprising: at least one of an air intake manifold and an air intake duct receiving a stream of combustion air from said turbocharger; wherein at least a portion of said intake manifold and/or said intake duct is made of plastic material; a charge air cooler module arranged at an interior of said air intake manifold, said charge air cooler module comprising a charge air cooler including a charge air cooler coolant inlet port; a charge air cooler coolant outlet port; an air inlet configured to receive said stream of combustion air from said turbocharger; a cooled flange integrated with said charge air cooler as unitary one-piece charge air cooler module, said cooled flange cooled by said charge air cooler, said cooled flange arranged on an exterior of said air intake manifold; an EGR inlet port integrated with said charge air cooler, said EGR inlet port extending through said cooled flange from an exterior of said air intake tract into said interior of said air intake manifold; an EGR inlet device arranged in the charge air cooler module and upstream of and proximate to the air inlet of the charge air cooler, said EGR inlet device including: at least one EGR outlet port positioned within the said intake tract, said EGR outlet ports configured to inject and mix exhaust gas with said combustion intake air in said intake tract; wherein said at least one EGR outlet port direct exhaust gas towards said air inlet of said charge air cooler; wherein said EGR inlet port is connected to said EGR inlet device, said EGR inlet port delivering exhaust gas to said EGR inlet device; wherein said at least one EGR outlet port is configured to inject and mix exhaust gas with said combustion intake air in said intake tract before entering the charge air cooler; wherein said charge air cooler is positioned downstream from said EGR inlet device and EGR outlet ports and positioned to receive said exhaust gas and intake air mixture.