R.J.
I am soooo happy the 2 of you have fixed the problem. Huzzah! We had a similar thing with diaper wipes, including trips to the ER and it basically being a fluke that we figured out what the cause was, aka, he's allergic to them.
To me it DOES sounds less like a chemical burn and more a contact dermatitis (aka an allergic reaction to something that is touched). Which is an important distinction... because it means he's allergic to SOMETHING in the carrier... the fabric/ polyester/ fire retardant/ etc.... and the next time he comes into contact with the same substance he'll have a similar reaction.
Here's a link with some great info from a very trustworthy site.
http://www.emedicinehealth.com/contact_dermatitis/article...