Abstract: A phosphorus-containing flame retardant is produced by preparing a reaction mixture, the reaction mixture including a phosphonic acid, a solvent for the phosphonic acid, and a metal or suitable metal compound, and reacting the phosphonic acid and the metal or suitable metal compound under conditions as described herein. The chemical composition of the resulting flame retardant product leads to excellent flame retardancy and exhibits high thermal stability. The presently disclosed flame retardants are useful, for example, in polymer compositions, particularly thermoplastics processed at high temperatures, over a wide range of applications.

Abstract: The present disclosure provides for the production of non-halogenated phosphorus containing, thermally stable flame retardant materials directly in the form of a powder or small particles. The process generally includes heating one or more phosphonic acid salts in a high boiling, water miscible, acid stable solvent to dehydration reaction temperatures of 200° C. or higher.

Abstract: A phosphorus-containing flame retardant is produced by reacting at a reaction temperature a mixture including a metal or suitable metal compound and a stoichiometric excess relative to the metal or suitable metal compound of an unsubstituted or alkyl or aryl substituted phosphonic or pyrophosphonic acid, wherein the phosphonic or pyrophosphonic acid is in a molten state at the reaction temperature. The chemical composition of the resulting flame retardant product leads to excellent flame retardancy and exhibits high thermal stability. The presently disclosed flame retardants are useful, for example, in polymer compositions, particularly thermoplastics processed at high temperatures, over a wide range of applications.