The range of applications involving free-radical cross-linking
processes has grown impressively over the last decades. However, in
numerous fields where tightly cross-linked materials are required,
the network development and its relation to the elastic properties
are still a gray zone, as it is particularly challenging to design
experiments that would allow validating the predictions from (often
phenomenological) theoretical models or numerical simulations. Here,
we report on a successful attempt to align time-resolved infrared-rheology
measurements with fully atomistic simulations over the whole conversion
range of an important acrylic free-radical cross-linking polymerization,
unveiling the different regimes behind the elasticity build-up upon
double bond conversion. Our combined experimental–theoretical
approach provides an original insight into the various stages of the
polymer network growth, from the earliest initiation up to final conversion.
More specifically, we show that the pregel and gel formation stages
are driven by the formation of branched polyfunctional polymers, which
link together toward a sample-spanning network at the gel point. This
regime proceeds in the postgel stage until the spatial heterogeneity
in the cross-link density vanishes, leaving dangling ends as residual
structural defects that then gradually connect to close the network.
Following a steep transition at ultimate conversion, the elastic modulus
of the network reaches the value predicted by the rubber elasticity
theory in the affine limit.